Take advantage of these free on-floor sessions. The Gear Expo Solutions Center is back for 2017 and has more presentations than ever before.
Tuesday, October 24
Induction Heat Treating Symposium
For more information, visit ASM’s Heat Treat 2017 site.
EMAG (P)ECM Technology – Introduction to ECM, Gear Broaching
Michael Hively, EMAG LLC
Please join us for an introduction to EMAG L.L.C. and ECM. Electro-Chemical Machining (ECM) is the generic term for a variety of electro-chemical processes. ECM is used to machine workpieces through the anodic dissolution of metal. Specifically, we will discuss replacing the conventional machining of gears with ECM, and the benefits. The process is used in aerospace engineering as well as the automotive, construction, medical equipment, microsystem and power supply industries. Almost all kinds of metal can be electro-chemically machined, especially high-alloyed nickel- or titanium-based ones, as well as hardened materials.
Advanced Burner Technology for Heat Treating
Steven R. Mickey, WS Thermal Process Technology
This presentation will describe WS burners and the many advantages that they offer such as longer life of both radiant tubes and burners, reduced and simplified maintenance, improved temperature uniformity, lower NOx emissions, and higher efficiency.
Precision Workholding Pays Dividends
Larry McMillan, HAINBUCH America
Whether you’re hobbing, grinding or shaping, small lot sizes in gear manufacturing has created a greater demand for flexible workholding with quick changeover and more precision. Peter Muller will discuss the latest innovations in gear workholding technology and how to enhance machine productivity.
Optimizing Speed, Accuracy and Reproducibility in Metallographic Preparation and Hardness Testing of Heat Treated Materials
Dr. Mike Keeble, Buehler, A Division of ITW
In many production environments, the speed at which quality control assessments can be made is critical to maintaining business efficiency. There is a perception that a fast result means a compromise in accuracy or reproducibility. This presentation will cover fundamental concepts in metallographic preparation and hardness testing of heat treated materials focused on helping attendees optimize efficiency and reproducibility without compromising quality.
Using The Ordinary to Make Your Reliability Extraordinary!
Devin Jarrett, Noria Corporation
Are you under the impression that new lubricants are clean? Although most manufacturers claim to make quality products, not every manufacturing process is of the highest quality. Discover how certain processes can lead to poor cleanliness for new lubricants. Most organizations would very happily accept a 99.9% AQL (Acceptable Quality Limit) which refers to the worst tolerable process average that is still considered acceptable. Given the current rate of oil production you would be stunned at how much oil is produced worldwide just by the top 10 producers, and how much of that is potentially out of spec or in some cases bad. In this session, the attendee will learn just how much lubricant in the market is potentially harmful and some strategies to help guard your equipment against failure and thereby increase your reliability.
Paul Boris, Vuzix
Boris, an expert in the Industrial Internet of Things (IIoT) and how manufacturers now have the ability, even with minor investment, to have IIoT projects in their factories that can provide actionable results, will be discussing IIoT in his presentation: The Industrial IoT is Here – and Manufacturers at ALL Levels Can Implement and Find ROI Quickly.
His knowledge and passion for the IIoT movement will bring a whole new level of emerging technology to Gear Expo. He will focus on the value proposition of IIoT for all manufacturers, regardless of size and provide tangible take-aways that can be implemented into plants to begin or further businesses’ IIoT strategy.
Insights on State-of-the-Art Quality Control
Kelsey Torboli, Struers Inc.
Learn how to prepare and test for case depth on surface hardened helical gears using an automated and reproducible process. In this materialographic presentation, we describe the procedure and method for determining the case depth of surface hardened helical gears. With highly-automated equipment and well-proven methods, it is possible to create an efficient and reproducible quality control.
Extended System Calculation for Gearboxes: Analytical Calculation and FEM are Growing Together
Dipl. -Ing. Gunther Weser, GWJ Technology GmbH
Based on the software “SystemManager”, a true system calculation will be presented. A closer look is taken at the combination of FEM and analytical methods in just one calculation system and which interactions can occur, for example in the case of planetary gear trains or housings. External FEM programs are no longer required, the user just needs the “SystemManager” to do the FEM calculations together with the analytical calculations e.g. for gears according to different standards like DIN 3990, ISO 6336 or ANSI/AGMA 2101/2001. The influence of the bearing and housing stiffness is also considered. Selected examples will be shown.
Maintenance Tips for Maximizing Your Furnace’s Life Span
Jim Grann, Ipsen
Knowing how to properly maintain and troubleshoot your furnace system is an excellent way to protect your investment, as well as minimize downtime, ensure a long life and cut down on operational costs. This presentation will cover key areas for properly maintaining and troubleshooting your vacuum furnace, from performing cleanup cycles to following maintenance best practices.
Detection of Gear and Sprocket Tooth Imperfections and Improper Heat Treatments Using Electromagnetic NDT Technology
Seth Connor, Foerster Instruments Inc.
Foerster is a world leader in eddy current and other electromagnetic NDT methods. Recently several noteworthy advancements in technology have been made. This presentation will feature a demonstration of the practical ability to detect imperfections on sprocket & gear teeth using eddy current. An overview of Foerster’s component testing products and a brief demonstration of detecting improperly heat treated parts by magnetic induction will be given. They will also show new flexible ribbon sensors. Foerster’s target is high speed inspection of every produced component, integrated directly into the production line. Videos of their automated NDT solutions will be shown.
Virtual Gear Machining: An Introduction to Studying Gear Cutting with FEA
Cory Arthur, Third Wave Systems
Interested in reducing manufacturing costs, improving gear quality and improving the ROI of R&D efforts? Do you find trial-and-error testing to be too slow and costly for the constant improvements the gear industry requires? It’s possible to make these adjustments and improvements by utilizing virtual gear machining to make modifications to your gear cutting process. The finite element analysis (FEA) solution AdvantEdge Gear Machining from Third Wave Systems is the virtual gear machining solution that simulates cylindrical hobbing and spiral bevel gear cutting processes. This presentation will include an overview of the software, simulation results, experimental validation and example use-cases.
Improve Your Heat Treating Process and Increase Productivity by Replacing Dissociated Ammonia
Steve Mueller, Praxair, Inc.
The furnace atmosphere is a key enabler for achieving precise, reproducible results, especially for heat-treating operations. If you are currently using dissociated ammonia in your furnace and are having issues with furnace downtime, maintenance, or throughput, there may be a way to resolve this. Nitrogen and hydrogen gases, mixed to accurate ratios, take away the ambiguities of inconsistent ammonia-based atmospheres and eliminate the quality problems resulting from a fluctuating furnace atmosphere. In addition, other benefits may appeal to your overall process including wide range of hydrogen concentrations, unique mixtures for multiple furnace configurations and quick, easy start-ups and shut downs.
Wednesday, October 25
Plenary Session/Induction Heat Treating Symposium
For more information, visit ASM’s Heat Treat 2017 site.
Nitriding as a First Choice for Surface Treatment of Gears
Dr. Edward Rolinski, Advanced Heat Treat Corp.
Properties of nitrided layers, in many situations, overcome those of carburized layers. For gears, nitriding has been underestimated due to perceived higher heat treatment costs. This is not necessarily true when all the costs of processing are considered. In many situations, a properly applied nitriding surface thermochemical treatment (both plasma or gas) can avoid part distortion and the requirement for final machining, both common occurrences with carburizing. Yet, nitriding offers a durable case and comparable performance. Discussions will be centered around material selection and properties that can be expected when nitriding thermochemical treatments are utilized for gears.
Improve Your Quenching Through CFD and Testing
Andrew Banka, Airflow Sciences Corporation
Insufficient or uneven quenching can result in failure to meet property specifications along with excessive levels of distortion and residual stress. While quenching rate and uniformity are largely controlled by flow of quenchant delivered to the load, consideration of the flow fields within quench systems has only recently received the attention it deserves. This presentation will provide an overview of simulation and test methods used to assess and improve quenching systems. Examples of past successes will be included.
Human Machine Interface (HMI) in Gear Manufacturing – “Documentation is not a Substitute for an Intuitive Interface”
Yefim Kotlyar, Machine Tool Builders
While setting up a new part, a cutting/grinding machine operator has to painstakingly enter a lot of gear and other data that could quickly turn into a frustrating and time consuming experience. This presentation will touch on changing expectations of gear manufacturers who increasingly require friendlier and therefore more efficient HMIs. This presentation will showcase some feature of an HMI that would improve machine efficiency and make the operator’s experience more pleasant. Visual verification of gear data entered, availability of defaults for the required fields, generous output with maximum amount of helpful info are just a few examples of a friendlier and more efficient HMI.
Process Automation – Taking Advantage of Recipe Selection Using Barcode Scanning Technology and Database Integration
Bob Fincken, Super Systems Inc.
Scrap and re-work are consistently areas, which heat treaters are always trying to minimize. This presentation will provide case studies on how companies reduce errors using process cycle automation by integrating SCADA packages with shop management system and take advantage of barcode capabilities to ensure operators maintain efficient and repeatable process controls.
Keep It Simple Stupid (KISS)
Bill Miller, Kapp Group
Gear grinding speed is approaching a technology plateau. There is much room for improvement in preparation for grinding. This presentation outlines the strides made in simplifying and shortening the setup for generating grinding. On-board inspection is just one of many features that have lowered the degree of difficulty. The intelligent gear grinding machine today has more than just powerful software and a simple user interface. Hardware features have emerged on gear grinders for bolt free, indicator free fixture change and auto sequence tool change. Worm dressing tools and new techniques further simplify setup of modified tooth geometries. Deployed in combination, the intelligent gear grinder is more than economical for small batch requirements.
Value Based Vacuum Measurement
Dan Saenz, Televac
While there’s considerable cost associated with the initial purchase of a furnace, maintenance over the life of the furnace is also a very significant investment for the end user, and this investment is often overlooked. Whether this cost is related to vacuum gauging calibration, cleaning, replacement, or downtime related to all of the above, Televac products are specifically designed to reduce maintenance costs for the end user while maintaining a design that’s simple for OEM furnace manufacturers to integrate into their systems. This provides clear benefits for both OEM furnace manufacturers and end users alike.
Dr. Rob Ivester, Advanced Manufacturing Office
Dr. Robert W. Ivester currently serves as the Deputy Director of the Advanced Manufacturing Office (AMO) in the Office of Energy Efficiency and Renewable Energy. AMO is focused on creating a fertile innovation environment for advanced manufacturing, enabling vigorous domestic development of new energy-efficient manufacturing processes and materials technologies to reduce the energy intensity and life-cycle energy consumption of manufactured products.
Prior to this position, he served as the Executive Secretary to the Inter-agency working group on Advanced Manufacturing, which was formed in 2011 under the National Science and Technology Council’s Committee on Technology in the Executive Office of the President, which produced the February 2012 report A National Strategic Plan for Advanced Manufacturing. His research interests include manufacturing process metrology, modeling, and optimization. He has performed research to quantify uncertainty associated with measurements and model-based predictions of manufacturing process behavior. In particular, he has performed extensive research on the measurement of temperature and strain during metal cutting.
He has been an instructor for the Johns Hopkins University Engineering for Professionals program for graduate-level studies in manufacturing engineering since 2001. He is a Fellow of the American Society of Mechanical Engineers and received his Ph.D. and Bachelor of Science in Mechanical Engineering and Master of Science in Manufacturing Engineering from the University of Massachusetts at Amherst.
Endurance Steels: Combining Strength and Toughness for Increased Power in Your Gear Set
Buddy Damm, TimkenSteel Corporation
Increased power density in gear sets means greater durability – allowing the use of existing designs to achieve higher horsepower and torque capabilities, or reduced size and mass for lightweighting. With TimkenSteel’s family of high-strength, high-toughness Endurance steels, grades with equivalent or better toughness than common gear steels are available at affordable prices. We compare strength, fatigue and toughness properties of Endurance grades to a range of common case-carburized gear steel properties. This analysis illustrates the potential to gain 45 percent more horsepower for an existing gear set, or to achieve the same horsepower with a 30 percent lighter gear set.
Automotive Workholding Technology for Turning
Kyle Zellmann, SMW Autoblok Corporation
Lean Manufacturing: Why quick change chucks even in high quality production environments. The complexities of manufacturing thinwalled parts. Why sealed chucks matter: hint, it’s not about low maintenance.
Precision Non-contact Temperature Measurement for Metal Heat Treaters
Michael Mackin, AMETEK
The presentation introduces non-contact infrared temperature measurement for metals heat treating applications. What processes benefit from these kinds of measurement, why this technology can be advantageous and why it is the only way to take measurements accurately? Infrared non-contact pyrometer model variants allow users to select thermometer type, temperature range, spectral response and optical characteristics to suit applications from 50 to 1800 °C/ 122 to 3272 °F. Many examples are discussed for heat treaters requiring temperature measurement at induction hardening, carburizing, plasma nitriding and CAL line positions, as well as in difficult to access locations.
Material Choices for Custom Bearing Application
Chris Napoleon, Napoleon Engineering Services
Not all bearing materials are created equally and choosing the right material might make a world of difference in your application. Napoleon Engineering Services manufactures custom bearings from a variety of materials to maximize corrosion resistance, fatigue life, or extreme environment conditions. Chief Engineer, Chris Napoleon, will discuss the use of different bearing materials and why they are used to solve application problems. He will cover 52100, M50, M50NIL, Pyrowear675, 440C, Cronidur30, XD15NW, and NiTiNOL60.
Hybrid Forging: Advances in Open Die and Closed Die Forging
Jeremy Copley, Scot Forge
Today’s high-strength material users are increasingly obliged by everyday economic and competitive realities to seek alternatives to their current manufacturing processes. The reality that forgings can be used for more than simple parts — and forged at very large sizes and unique geometries — is slowly being realized. Companies who are looking for a better competitive advantage have started seeking the help of forging facilities with the metallurgical know-how to deliver improved products, processes and – especially – costs. This presentation will outline how, using the advantages of open die forging combined with the near-net shape capability of closed die forging, the forging process can be tailored to optimize time and cost savings for the gearing industry.
Best Methods of Operation & Maintenance for Vacuum Furnaces that Really Work!!!
Rob Huckins, G-M Enterprises
With over thirty years of experience in the Thermal Processing Industry, G-M Enterprises has the experience and resources to consistently meet its overall customer’s heat processing needs developing a variety of new innovative products, timely manufacturing, an extensive array of prompt quality services. Our dedicated staff at G-M Enterprises, with over 400 years of accumulated vacuum and atmosphere thermal processing experience, has made us a leader in manufacturing “State-of-the-Art” Vacuum and Atmosphere Furnaces, quality Replacement & Rebuild Hot Zones that “REALLY” work across the globe. In this presentation we will share experiences and best methods to optimize your vacuum furnace performance.
Thursday, October 26
Induction Heat Treating Symposium
For more information, visit ASM’s Heat Treat 2017 site.
Clean Steel for Gear Design
Jamie Price, Ovako
Ovako presents how/why clients use clean steel to unlock new gear designs and avoid fatigue.
Near Net Gear Forging Technology
Jack Masseth, Meritor Inc.
Highlights the benefits of near net gear forging technology in the areas of; raw material savings, manufacturing cost savings, and product performance improvements.
Continuous Monitoring/Continuous Monitoring & Control
Jackie Walker, Houghton International
The GREENLIGHTTM Andon Fluid Monitor is a completely self-contained measurement system which sets the new standard for continuous concentration monitoring of metalworking fluids such as aqueous quenchants for heat treatment applications. We also will be talking about The Houghton® ACTS™ Fluid Monitor and Control System is completely self-contained and represents a new standard in metalworking fluid property measurement and control.
Distortion Controlled?! – The UniCase Master®
Bill Warwick, SECO/WARWICK
Case hardening processes have historically been processed in atmosphere furnaces and quenched in oil. The equipment used in this processing includes rotary hearth, pusher, and roller continuous internal oil quenching equipment. This equipment, being over half a century old, does little to control distortion of parts. But that was the beginning and the UniCase Master® is now. It is the next evolution in high temperature processing that uses low pressure carburizing/high pressure gas quenching with true single piece flow and offers an as of yet unmatched distortion control capability.
Jay Rogers, Local Motors
Local Motors – a technology company that uses a co-creating community to design, develop and build Olli, the world’s first self-driving cognitive vehicle – is redefining the development of connected hardware by pairing micro-manufacturing with the open source technology community.
They are the first company to utilize Direct Digital Manufacturing (DDM), debuting the world’s first 3D-printed car, the Strati, in September of 2014. This type of innovation works well with Gear Expo’s drive technology focus and AGMA’s strategy of bringing emerging technology to the gear industry.
“I’m excited to be speaking at Gear Expo, where I’ll be sharing my experiences with taking risks in this ever-evolving industry, as well as my collaboration with small-volume manufacturing and car-loving communities,” said Rogers.
Forming and Hardening Plate and Gears in a Single Manufacturing Chain
Randy Schuster, Wickert Hydraulic Press USA
Wickert developed multiple systems for automotive gear hardening and agricultural part forming/hardening. These systems generally comprise a component feed with a component buffer, a high-temperature atmosphere furnace, with presses with integrated quenching. Process incorporates quench liquids of water, polymers or hardening oils. Wickert’s system for gear hardening provides accurate ID tolerances and minimizes warping of delicate irregular gears shapes. Thereby reducing costs to manufacture gears while providing for flexible production stream with quick automated tool changing the system provides for flexibility of parts in the hardening process keeping production running even when there are manufacturing interruptions in the upstream supply.
How Non-Contact Optical Pyrometry Improves Temperature-Measurement Accuracy, Repeatability, and Reliability
Mark Ritzheimer, Advanced Energy Industries, Inc.
Today’s optical pyrometers meet the challenges of industrial manufacturing with a variety of advanced features and functions that support accurate measurement and control, regardless of process conditions. This presentation describes design principles behind the most sophisticated non-contact optical pyrometers, and details how wavelength selection as well as energy and emissivity effects can impact a process. Engineers will learn how to build thermal profiles, how to take high-quality measurements, and which factors are most important in specifying pyrometers for the best performance to support the long-term success of a manufacturing process.
Wisconsin Oven’s Horizontal Quench System Offers a High Tech Alternative to Drop Bottom Furnaces
Doug Christiansen, Wisconsin Oven Corporation
Wisconsin Oven’s horizontal quench furnaces are a high tech solution treatment system that provides a compact, cost effective alternative to drop bottom furnaces. With quench times as low as 7 seconds, and a load capacity ranging from 2,000 to 6,000 pounds, the equipment can meet the requirements of AMS2770, AMS2750, BAC5602, and others. Operation is fully automated to insure the guaranteed quench time is met. The heart of the horizontal quench system is Wisconsin Oven’s standard draw batch temper furnace (aka companion draw furnace). With hundreds of draw batch units in the field throughout the world, the design is a well-proven workhorse.